Hobart Welding Products OM-240 438E manual Weld Test, Troubleshooting, Weld bead

Page 60

13-12. Weld Test

2 To 3 in.

(51-76 mm)

1/4 in. (6.4 mm)

3

2 To 3 in.

(51-76 mm) 2 2

1

1Vise

2Weld Joint

3Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

3

1

S-0057-B

13-13. Troubleshooting

Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Causes			Corrective Actions

Arc length too long.			Reduce arc length.

Damp electrode.			Use dry electrode.

Workpiece dirty.			Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
			welding.

			Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes			Corrective Actions

Amperage too high for electrode.			Decrease amperage or select larger electrode.

Arc length too long or voltage too high.			Reduce arc length or voltage.

			Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
			weld bead.

Possible Causes	Corrective Actions

Insufficient heat input.	Increase amperage. Select larger electrode and increase amperage.

Improper welding technique.	Place stringer bead in proper location(s) at joint during welding.

	Adjust work angle or widen groove to access bottom during welding.

	Momentarily hold arc on groove side walls when using weaving technique.

	Keep arc on leading edge of weld puddle.

Workpiece dirty.	Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
	welding.

OM-240 438 Page 56

Image 60

Contents OM-240 438E ProcessesDescription From Hobart to You Protect Your InvestmentTable of Contents 10-1 Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can burnFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Hydraulic Hazards Compressed Air HazardsHydraulic Equipment can injure or kill Hydraulic Fluid can injure or killCompressed AIR can injure or kill Fire or Explosion hazardOverheating can damage motors Falling Equipment can injureCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Implanted Medical Devices Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Pièces Chaudes peuvent provoquer des brûlures LES Fumées ET LES GAZ peu- vent être dangereuxLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut provoquer des blessures Les Pièces Mobiles peuvent causer des blessuresLES Étincelles À L’ÉCHAPPEMENT peuvent provoquer un incendie LA Chaleur DU Moteur peut pro- voquer un incendieLire LES Instructions Risque D’INCENDIE OU LA Chute DE L’ÉQUIPEMENT peut provoquer des blessuresLE Surchauffement peut endommager le moteur électrique LES Étincelles Projetées peuvent provoquer des blessuresProposition californienne 65 Avertissements UNE Remorque QUI Bascule peut provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécurité Informations relatives aux CEMEn ce qui concerne les implants médicaux − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Weight 562 lb 254 kgDimensions For Units With Optional Running Gear DimensionsDuty Cycle Duty CycleFor CC/AC Mode For CC/DC ModeVolt-Ampere Curves Generator Power Curve Fuel Consumption− Installation Installing Welding GeneratorSerial Number And Rating Label Location Movement Location / Airflow ClearanceGrounding Generator To Truck Or Trailer Frame GND/PEEngine Prestart Checks OilInstalling Exhaust Pipe Connecting Or Replacing the BatteryConnect negative − battery cable last + −Connecting To Weld Output Terminals Stop engine Failure to properly connectTools Needed 3/4 Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m 100 150 200 250Start Your Professional Welding Career Now Engine Control Switch − Operating the Welding GeneratorFront Panel Controls Fine ControlCold Weather Engine Operation InfrequentlyLoaded Frequently LoadedTypical Stick Welding Connections And Control Settings Stop engineElectrode − Operating Auxiliary Equipment Standard ReceptaclesGfci Receptacle Option At least once a month, run engine atSimultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle− Maintenance Maintenance LabelRoutine Maintenance 100200 500Servicing Air Cleaner Changing Engine Oil, Oil Filter, and Fuel Filter Stop engine and let coolClose valve and valve cap Before Adding Oil Running engineAdjusting Engine Speed Idle Speed AdjustmentWeld/Power Speed Adjustment Turn idle speed screw for fine ad- justmentsStop engine. Disconnect negative − battery cable Overload ProtectionServicing Optional Spark Arrestor Fuse F1 See Section− Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting Check receptacle wiring and connectionsErs SR2 and SR3 Check fuel level− Parts List Control switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts− Electrical Diagrams Circuit Diagram For Welding Generator240 424-B − Generator Power Guidelines Selecting EquipmentGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated Electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw GuidelinesWeld current starts when Electrode touches workElectrode and Amperage Selection Chart Striking an ArcScratch Technique Tapping TechniquePoor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle 10-30Conditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle NormalGroove Butt Joints Lap JointTee Joint Or LessTroubleshooting Weld TestPossible Causes Corrective Actions Weld beadLack of Penetration Good Penetration Good Penetration Excessive PenetrationMetal remains DirectionSOCKET/WRENCH Selection Table Standard Metric Service SupportAssistance Contact your Distributor for Hobart Welding Products